Pulse grading machine

Types of pulse grading machines

Pulse grading machines are essential tools for processing pulses. Many types of machines exist that can separate pulses based on a variety of factors including size, weight, color, moisture content, and even chemical properties. The following machines are the most popular varieties used in commercial settings.

• Screen-based grading machines

  Typically, a screen-based grading machine is set up with a series of screens with different mesh sizes. The raw material is fed into the machine, and as it shakes, large particles fall through the screens, while small ones are captured above. Usually, this type of machine is used for large grains or seeds.

• Optical sorting machines

  Optical sorting machines are equipped with cameras and light scanners that are able to detect variations in size, color, and shape. When a certain pulse is identified, the machine uses puffs of air to eject the undesired pulse into a separate container or track. Due to their automated sorting and high levels of accuracy, optical sorting machines are very popular in the industry.

• Wet-dry grading machines

  In a wet-dry grading machine, the pulse is sorted based on its moisture content. Those contents with high moisture levels are separated and/or dried before they are processed again. Because these machines help to reduce spoilage, they are often used in facilities with storage containers.

• Density separator machines

  Density separator machines function by separating pulses based on their weight. They use airflow to suspend the pulse and a weighted deck to separate them based on the densities. Sometimes, they are also referred to as air classifiers.

Specifications and Maintenance of Pulse Grading Machine

Specifications

Pulses grading machines are available in different specifications based on the demand of the users. The key specifications that matter for buyers include the dimension, the weighing system, the grading sieves, the power requirements, and the stability.

• Dimension: The dimension of the grading machine defines its capacity. A machine with a dimension of (LxWxH) 240x120x150 cm can grade around 800 kg to 1000 kg of pulses in one hour. Most machines have a three-foot stand which elevates the entire structure by another three feet. The grading area is between 4 and 5.5 feet.
• Weighing system: Modern machines have electronic weighing systems with software that can easily identify different sizes, shapes, and weights of pulses. The system also has the flexibility to set the tolerance limits of various pulses. Older machines used manual weighing with balance scales.
• Grading sieves: The base of the grading machine consists of sieves made of wood, metal, or plastic. The number of sieves varies according to the type of machine. Generally, there are 5 to 7 sieves with different mesh sizes. The sieves are vibrated by the motor so that the pulses can fall through the mesh into their respective containers.
• Power requirements: The pulse grading machine uses electrical power from the grid or standalone solar power. On an average, the machine consumes 1 HP to 2 HP of electricity during the grading process.
• Stability: The machine has four feet made of cast iron or mild steel. The three-foot stand provides adequate stability during the grading process. Some machines come with wheels so that they can be moved around in the facility easily.

Maintenance

Maintenance of the grading machine is essential for operational efficiency, longevity, and the safety of workers. A well-maintained machine will grade pulses accurately and ensure minimum wastage.

The maintenance schedule can be done weekly and monthly.

• Weekly tasks:
• Clean the exterior and interior of the machine to remove any residue and dust.
• Lubricate the vibration rod and the moving parts with oil or grease.
• Check the fasteners and bolts, and tighten them if required.
• Monthly tasks:
• Develop a cleaning schedule for the sieves based on the type of pulses processed in the machine. Remove the sieves and clean them thoroughly.
• Oil the lubrication points as advised by the manufacturer. Check the vibration rod for any damage, and replace it if necessary. Lubricate the bearings and the moving parts of the rods.
• Carry out routine electrical checks, and inspect the wires and electrical connections. Check for any fraying or wear and tear.
• Balance scales and digital weighing machines need to be calibrated at least once a month or more depending on usage.

Uses of pulse grading machines

A rice grading machine has many uses in the agricultural sector. Companies that handle various crops, such as pulses, rice, wheat, and coffee beans, use the machine to ensure quality control when packaging their products.

The primary use of the grading machine is to separate whole and damaged grains. The machine uses a sieve with holes of different sizes to pass through small grains while large grains fall down. This is how damaged grains, such as weeviled, sprouted, stained, or discolored grains, are weeded out.

Public and private institutions also use grading machines to ensure quality control. These institutions use the machines to separate crops based on age, size, and weight. Correcting mistakes that produce inferior grades can save companies' reputations in several industries.

Consumers want to know the food they purchase has been carefully graded, so salvage firms get higher prices when using a grading machine.

Buyers who spend money on whole pulses can easily find them with the help of the grading machine. A pulse grading machine is widely used in the Dhals industry to ascertain the quality and make a better profit.

Homeowners can also use a small-scale grading machine. They usually use it to separate contaminated crops before cooking. Homeowners do not have a large demand for graded crops as commercial homeowners. The small-scale grading machines are affordable and make them suitable for home use.

How to choose a pulse grading machine

When purchasing a pulse grading machine, buyers should explore different types, focusing on their specific needs. It is crucial to evaluate the machine's capacity and make sure it can handle the desired volume of pulses within the set timeframe. Moreover, buyers should consider the machine's accuracy and its ability to grade pulses with precision. To achieve this, they can seek models with advanced sensing technologies and adjustable grading parameters.

Also, buyers should prioritize machines that are user-friendly. As such, they should opt for machines with intuitive controls and straightforward operating procedures. Additionally, they should consider the machine's cleaning and maintenance requirements, as this can have a significant impact on production efficiency. If the machine has complex cleaning requirements and maintenance processes, it can result in downtimes that can affect productivity.

More importantly, buyers should choose grading machines that are compatible with the type of pulses they handle. For instance, some machines can efficiently handle round pulses such as lentils, while others are better suited for elongated pulses such as smooth beans or split peas. In addition to this, buyers should take time to research into the machine's construction materials and build quality. This will go a long way in ensuring durability and a successful grading performance.

Buyers should also look for grading machines with different modes of operation. For instance, some machines can handle high-speed production but at a relatively high noise level, while others operate at lower speeds and with much more quieter operations. If possible, buyers should test the machine before purchasing it, as this will give them more information about its performance and functionality. Finally, buyers should choose a reputable manufacturer or supplier to ensure they have a quality pulse grading machine that will meet their expectations and requirements.

Pulse grading machine FAQ

Q1: Which types of pulses need grading before milling?

A1: Not all pulses require grading. High-value pulses that fetch a premium, such as black matpe, green gram, and red gram, are typically graded before milling. Moreover, large-scale buyers who purchase processed pulses for commercial use also demand that pulses be graded before milling.

Q2: What are the latest advancements in pulse grading technology?

A2: The newest advancements in pulse grading technologies involve the use of artificial intelligence (AI) and optical sensing. AI can be used to automatically fine-tune grading parameters, while optical sensors can detect color variations, size, and shape.

Q3: What are the challenges of using a grading machine for pulses?

A3: The main challenge of using a grading machine for pulses is the lack of standard grading categories. This makes it difficult to develop a machine that meets the needs of all customers. Moreover, different types of machines are required depending on the buyer's specifications. This may require additional costs and expenses for research and development.

Q4: What are the advantages of installing a pulse grading machine in one's facility?

A4: The main benefits of using a pulse grading machine are economic. The machine can easily and quickly process large amounts of product. It can handle items from different sizes and small to large volumes. The final product will have a higher market value, which will enable the grader to recoup the machine's cost and make a profit.

Q5: How does a mechanical pulse grading machine differ from an electronic one?

A5: Mechanical machines rely on manual processes and physical components, such as levers and vibrating screens, whereas electronic machines utilize electrical and electronic components, such as motors and sensors.